Background

After completion of phase II of the project KPO now operates the following facilities: the Karachaganak Processing Complex (KPC); the gas and liquids separation and re-injection plant – Unit 2; the gas and liquids separation plant – Unit 3; and the export pipeline Karachaganak-Bolshoi Chagan-Atyrau.

AVENCOM Responsibility

In 2016, under the current contract for the maintenance of HVAC systems, KPO B.V. asked us to prepare a work pack for the modernization of HVAC control system based on Honeywell and Siemens. The equipment of the existing control system was outdated and spare parts were not produced.

AVENCOM Approach

In a short time, we prepared documentation for more than 40 technological process buildings of UNIT-2 and KPC plants: we planned to replace obsolete equipment with Honeywell XCL8010 and XFL8 … and Siemens PXC and TXM. In the same year, AVENCOM was awarded a contract to replace Honeywell and Siemens control systems in ten buildings at UNIT-2. To accomplish this task, we have involved equipment manufacturers. The scope of work included:

• Writing programs (firmware) for controllers in accordance with the current control philosophies;
• Dismantling of obsolete equipment and installation of new equipment;
• Connection configuration;
• Carrying out a functional test for the conformity of cause-and-effects, including with imitation of the incoming signals “Fire”, “Gas”;
• Handover of a completed work to the Customer;
• Preparation of as-built documentation.

During the installation works, it turned out that the existing termination of the control cables was too short, and therefore we had to completely change the termination of the cables.

All equipment replacement work was carried out without withdrawal the HVAC systems from service, in this regard, the ventilation equipment was switched to manual mode and supported by operators. In the course of the work, it was possible to identify malfunctioning drive devices that were reconfigured.

The works were successfully completed and the systems were handed over to KPO B.V. into operation.

In 2017, AVENCOM received another contract to replace Honeywell and Siemens control systems in 32 buildings at KPC. We also involved equipment manufacturers. The scope of work included:

• Writing programs (firmware) for controllers in accordance with the current control philosophies;
• Dismantling of obsolete equipment and installation of new equipment;
• Connection configuration;
• Carrying out a functional test for the conformity of cause-and-effects, including with imitation of the incoming signals “Fire”, “Gas”;
• Handover of a completed work to the customer;
• Preparation of as-built documentation.

In the course of work in one of the buildings, a discrepancy was found between the single line diagram and the termination of control elements of existing control panels, therefore, we updated the diagrams in excess of the contractual scope of work.

As at UNIT-2, all work was carried out without withdrawal the HVAC systems from service.

Summary

The works were successfully completed and the systems were handed over to KPO B.V. into operation.